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The year 2025 promises to be another significant period of growth and innovation for direct to film technology. Colin Marsh, managing director of Resolute, outlines what you can expect to see coming during the next 12 months.
Both textile and UV DTF printing are continuing to advance rapidly, carving a substantial path through the decoration industry.
Given that DTF is already faster and more economical than many other decoration processes, it might seem challenging to envision further improvements. However, there are two key areas with considerable potential for development. The following predictions are based on current trends, ongoing developments, and some speculative insights.
The craft market and purpose-built DTF systems
One of the most notable gaps in the market is the lack of purpose-built DTF systems for the craft market.
Currently, converted desktop printers dominate this space. However, it is anticipated that we will see the introduction of purpose-built DTF printers priced under £3,000 by sometime in 2025.
When we refer to ‘purpose-built’, we mean roll-fed systems equipped with print heads specifically designed for white and colour pigmented inks, with integrated white ink management systems – not aftermarket add-ons.
These features are typically absent in converted desktop printers, which, despite modifications, cannot match the reliability and performance of a purpose-built DTF printer.
The anticipated breakthrough will likely come in the form of a 33cm desktop roll-fed device utilising a single print head to keep costs down. There are impressive advancements in software technology aimed at speeding up the use of single print heads. While in-line printing has been around for some time, managing white ink, CMYK, and, with UV DTF, a clear varnish through a single print head requires sophisticated technology to achieve speeds of around 10 meters per hour.
If we’re fortunate, we might even see some of these innovations showcased at Printwear & Promotion LIVE! 2025 next month.
Advancements in High-End DTF
High-end DTF printing also has significant room for improvement. There is an ongoing debate about whether using multiple systems inherently offers more reliability. However, this approach increases labour costs due to the need for more operators, presenting a double-edged sword for businesses. Multiple print head devices, featuring anywhere from 8 to 15 print heads, can achieve impressive throughput. However, they come with higher costs for purchase and maintenance and require more physical space – an expensive commodity in any expansion plan.
The future of high-end DTF likely lies in using fewer print heads combined with intelligent software to boost speeds. This approach can result in smaller, more cost-effective printers. However, curing at higher speeds introduces its own set of challenges. The two-stage process of curing ink and melting powder requires precise time and temperature control. Errors in this process can result in transfers that are either oily or over-cured, leading to cracking and reduced opacity and durability in the wash. Simply increasing the temperature is not a solution, as it can cause the ink to boil, leading to pin holing.
To achieve a stable, well-cured transfer, curing units will need to be longer to maintain a consistent temperature for the required cure time. This is where we might see the emergence of multi-layer vacuum belt curing units.
These units not only save space but also utilise vertical space, which is often underutilised. With ink loading at a maximum to ensure good opacity, a perfectly horizontal film path is essential to prevent ink from bleeding off the page. Any downhill motion can result in poor quality prints, with more white ink at one end of the image than the other, assuming the ink does not run off the film before being powdered. Using high-speed, high-quality DTF ink combined with a good hot peel film will help mitigate these issues.
Conclusion
In conclusion, 2025 is set to be a transformative year for DTF technology. The introduction of purpose-built DTF printers for the craft market and advancements in high-end DTF systems will drive the industry forward.
As technology continues to evolve, we can expect to see more efficient, reliable, and cost-effective solutions that will further solidify DTF’s position as a leading decoration process. The future of DTF is bright, and the innovations on the horizon promise to make this technology even more accessible and effective for businesses of all sizes.
